1. Six Sigma Green Belt
Certification
Reduce rate of defects of powder coating
PROJECT LEADER : DINESH GOONARATHNE
8/28/2015

2. SIX SIGMA
Reduce rate of defects of powder coating process
Designed and implemented by
Mr. Dinesh Goonarathne
Project Leader
Project Members
 Mr. Amal
 Mr. Narada
 Mr.Suranga
 PROJECT CHAMPION : GROUP MANAGER, Mr. S.D.Kumarasekara
 Consultant :DMA Kulasooriya-ISL-Certified six sigma black belt
Alumex PLC
Hayleys Group
Pattiwila road,sapugaskanda,Makola,Sri lanka

3. SIX SIGMA
Table of Contents
1.0 Background....................................................................................................................................... 4
1.1 Company Profile............................................................................................................................ 4
1.2 Project organization……………………………………………………………………………………………………………..5
1.3 Problem Opportunity................................................................................................................ 5
1.4 Goal …………………………………………………………………………………………………………………………………… 6
1.5 Target…………………………………………………………………………………………………………………………………..6
1.6 Project Scope ………………………………………………………………………………………………………………………6
2.0 Problem is Defined........................................................................................................................... 6
2.1 Rate of Scraps ............................................................................................................................... 6
2.2 SIPOC ……………………………………………………………………………………………………………………………………….9
2.3 QFD ………………………………………………………………………………………………………………………………………….9
2.4 In-Out Matrix………………………………………………………………………………………………………………………….10
2.5 Measurement Stage Planning Sheet……………………………………………………………………………………….10
3.0 Defects Measure………………………………………………………………………………………………………………………..12
4.0 Defects Analysis ……………………………………………………………………………………………………………………… 15
5.0 Process Control………………………………………………………………………………………………………………………….17
5.1Parato chart .............................................................................................................................17
Discussion………………………………………………………………………………………………………………………………………..20

4. SIX SIGMA
Outline of the project
 Project title
 Project champion, leader and team members
 Business case & problem/opportunity statement
 Goals
 DMAIC Methodology
 Action Plan
 Resource Requirements-Budget
 Project implementation
 Project monitoring, Evaluation
 Celebration of results & Dash board
Project Title

5. SIX SIGMA
Reduce rate of scraps of powder coated profiles
1.0 Background
1.1 Company profile
RELATION WITH ALUMINUM POWDER COATING INDUSTRY
Process of ALUMININUM MANUFACTURING
 MELTING PROCESS
 EXTRUSION PROCESS
 POWDER COATING
 ANODIZING
 DIE DESIGN AND CORRECTION
My role in industry
Working on powder coating plant as in-charge of plant. In this section
approximately around 40 workers are working . The two polyester powder
coating plants have combined capacity of over 1,800 M/T per annum. Polyester
powder coating, also known as color coating on aluminum, is a solvent-free,
durable, factory-applied coating for aluminum substrates. It is a thermosetting
coating where the resin cross links after stove at around 220˙C (curing).
Powder coating offers protection against adverse outdoor weather
conditions. Its mechanical properties can be crafted to meet the varied
requirements of customers.

6. SIX SIGMA
1.2 Project organization
1.3 Problem/opportunity
Following reasons directly effected to the process which was increasing
rate of defects of powder coating.
LM
HM
P/C DAMAGE
OTHERDAMAGE
DUST/powder bowl
EXTUSION DAMAGE
ALUCHIP
Champion
Leader- Dinesh
Mr. Amal
Quality Manger
Mr.Suranga
Prod. Executive
Mr. Narada
Quality T.O

7. SIX SIGMA
1.4 Goal
 Remaining minimum reject rate Ex.2.5% monthly
 Higher production output within minimum time period.
1.5 Target
Highly customer satisfaction providing profiles and also reduced
cost of waste as scraps.
1.6 Project Scope
 Get the observation of defects categories
 Collection data production out and planning
 Finding out root case of coating process
2.0 Problem is defined
Nature of Customer Order
 No of Profiles
 Length of profile
 Section no
 Powder color
 Order No.
2.1 Burning Problem is high rates of scraps
Defect: Any damage or improperly (High /low micron thickness on profiles
ect.)

8. SIX SIGMA
Time Analysis
Problems born from manual racking
Reasons for this issues
 Racking Time is very high
 Racking mistakes are high
 Some times Nothing available profiles to racking
 High rate of powder coated scraps
Problem was why the varies time was taken to racking for same section code. That
problem is born from manual workers issue.
Solution : set the leader for racking and get the target value within 1 hour. The supervise the
target valve hour to hour.
Now time management is okay after take the above solution. So therefore no need to analysis
more and more because my major part is defect analysis.

9. SIX SIGMA
Six sigma quality Level of my plant
DPMO
Unit : Powder coated profiles given order
Defects : Scraps at completing order
Opportunities : CTQ ‘s of VOC
Area: Aluminium powder coating Manufacturing
Customer Quote: good condition profiles without low quality
CTQ Name: non damages
CTQ Measure: well surface finishing
CTQ Specification: profiles are properly (they will not properly if any individual
profiles are bad)
Unit: : A killo gram (Total cumulative out put production weight within time period)
Opportunity: may be defective issues in powder coating process
Units and Defects can be varied during time period.
Opportunities : 1.Gum Tape
2. Alu chips
3.low/High Microns
4.pin holes
5.powder dust/bull
6.water deposit
7. air bubbles

10. SIX SIGMA
2.2 Sipoc model
supplier Input Process Output Customer
Dispatch Mill finish item Surface finishing Readymade
items for
racking
Alu FAB
Stores Powder Powder coating Coated profiles N-Rich
Man power Manual Worker Racking and
Packing,
Loading/unloading,
Cutting
Help to process Aluroma
Stores Chemicals,
Acids,
Chromate
Pretreatment Treated profiles Sanken
Construction
Utility Diesel,
Electricity
Machinery
Operation
Finishing items MAGA
Engineering
Supplier Process Business Process Customer Process
CTS CTI CTP CTQ VOC
Store powder coating High quality Price
store chemicals Pre treatment Low rejects durability
Dispatch and
logistic Dep.
Mill finish
items
Surface cleaning &
racking
Regular
packing
Quality/Good
condition
utility Electricity
power
Automated process Delivery on
time
2.3 QFD Chart
 4-Strong
o 2-Medium
∆ 1-Week
importance
Surface
cleaning
Racking&
packing
Pre
treatments
Powder
coating
Machinery
operation
VOC
1. Price 5 ∆ o   o
2. Durability 4 ∆ ∆   ∆
3. Quality of
product
5  ∆  ∆ o
4. Delivery on
time
5   ∆ ∆ 
Total 49 39 61 46 44

11. SIX SIGMA
2.4 IN-Out Matrix
Scope In Out
Customers Dubai- Aluminium
Akzonobel
DGL
JOTUN
ALU FAB,Aluroma,
N-Rich,Salasi, MAGA Engineering, Sanken
construction
Product Al-Billet ,Powders,
chemicals
Powder coated Aluminum profiles
Process steps Order mill finish items
from dispatch
Surface cleaning , racking , pretreatment ,
powder coating , curing , packing
According to QFD chart
My critical process were Pretreatment ,surface cleaning and powder coating process.
2.5 Measurement stage planning sheet
CTP CTQ/CTI Operational
Definitions
Data
Type
Stratification Sampli
ng size
Freque
ncy
responsi
bilities
Pretreatme
nt
Nos. of
chemical cans.
How many liters
included to bath
Count Put the chemicals
every 6 hrs.
24 hrs. 3 Producti
on
Executiv
e (LAB)
Concentration
of bath
Measure the
conc. Of baths
time to time
contin
uous
Control the water
valve of bath
6 hrs. 3 P.E (
Plant)
Surface
cleaning
Supervis
or
Powder
coating
Auto booth
gun settings
Set the relevant
value of guns
Count Set values for
Every racks
15 min. 96 Gun
operator
Booth speed
(m/min)
Set the speed
according to
curing cycle of
item
Contin
uous
Depend upon
Changing the
powder category
Custom
er order
1 P.E
(plant)
Data Analysis for get the just only idea about process.

12. SIX SIGMA
Time Production output
12/07/2015 ; 24 hours 4051.15
13/07 5748.15
14/07 6140.7
15/07 4370.93
16/07 5562.8
17/07 5794.9
20/07 6539.8
0
1000
2000
3000
4000
5000
6000
7000
Production Output
Mean

13. SIX SIGMA
0
1000
2000
3000
4000
5000
6000
7000
production output
scraps
mean
3.0 Defects Measure
Description of Scraps in June month
June month (1/06/2015-30/06/2015)
Reject Rate : 6.82%

14. SIX SIGMA
Units 95270.5
Opportunities 7
Defects 6500.3
DPMO 9747
Yield(%) 99.03
Process Sigma 2.33
Production
Scraps

15. SIX SIGMA
Reject Rate : 4.93 %
0
1000
2000
3000
4000
5000
6000
7000
8000
1-Jul
3-Jul
5-Jul
7-Jul
9-Jul
11-Jul
13-Jul
15-Jul
17-Jul
19-Jul
21-Jul
23-Jul
25-Jul
27-Jul
29-Jul
31-Jul
Productionoutput Production in July
production output
scraps
mean
Production
Scraps
reject rate 4.933003
Production 126043.5
Scraps 6217.73

16. SIX SIGMA
Units/Kg 126043.5
Opportunities 7
Defects 6217.73
DPMO 7047
Yield(%) 99.30
Process Sigma 2.45
4.0 Defects Analysis
Compare June and July months.
Evaluation June July Target Difference
with target in
June
Diff. with
target in
July
Production
/Kg
95270.5 126043.5 135000 39729.5 8956.5
Scraps/Kg 6500.3 6217.73 3500 3000.3 2717.73
Reject rate % 6.823 4.933 2.6
Sigma level 2.33 2.45 2.68
Target sigma level
Units/Kg 135000
Opportunities 7
Defects 3500
DPMO 3704
Yield(%) 99.63
Process Sigma 2.68

17. SIX SIGMA
1332.86
1045.76
0.00
114.25
295.77
120.33
424.75
334.73
705.36
535.18
114.69
2.25
32.1
30.95 457.43
0 0 0
602.38
Low Microns
High Microns
Test or Trail Operation
Oil Patch
Powder Coating damage
Curing /Dry oven
problem/Back Initation
Carbon dust
Trasport Damage/Despatch
Dmage
Dust
Water Patch
Different reasons to defect and their percentage.
Mainly consider following defects and immediately reduce those reasons
 Low micron
 High micron
 Water deposit
 Dust (powder or surrounding )

18. SIX SIGMA
sample analysis of June month production
5.0 Process Control
5.1 parato chart
Cause for
defects
Frequency Cumulative
fre.
Percentage
%
Cumulative
%
Low Micron 15 15 38.46 38.46
High micron 12 27 30.77 69.23
Water Deposit 9 36 23.08 92.31
Powder Dust 3 39 7.69 100
Total 39
0
500
1000
1500
2000
2500
3000
3500
0
1000
2000
3000
4000
5000
6000
6/1/2015 6/2/2015 6/3/2015 6/4/2015 6/5/2015
Production
Scraps
Target

19. SIX SIGMA
Scraps summery of August 1st
to 10 th. 9 opportunities have in this month.
Low Micron 302.43
High Microns 14.19
Dust Environment 480.79
Powder Coating
Damage
45.30
Water patch 66.89
gum tape 49.55
oil patch 43.28
curing problem 16
powder dust 90.25
reject 1163.59
production 28500
Units/Kg 28500
Opportunities 9
Defects 1163.59
DPMO 4536
Yield(%) 99.55
0
20
40
60
80
100
120
low high water dust
frequency
cumu. Frq.
percentage %
cumu. Perc %

20. SIX SIGMA
Process Sigma 2.61
Net savings calculate
June month production :95.27MT
Defects :6.5MT
After improvement
Production :126.05MT
Defects :6.2MT
Production cost for 1kg :1200LKR
Productivity cost :(126.05-95.27)*1000*1200
: 36936000 LKR
Defect saving cost :(6500-6200)*1200
: 360000LKR
Net savings :37296000 LKR
Expected control chat after achieved the sigma level.

21. SIX SIGMA
Final result
Achievement factors June Month ( Start) July (After Improving
)
August ( Process
Control)
Process Yield 99.03% 99.63% 99.55%
DPMO 9747 3704 4536
Sigma Level 2.33 2.68 2.61
In here specially calculated data of august month only within 10 days. therefore
require target can not be reached.
Discussion
In this project I focused powder coating sections only our produced profiles not be defect when
consider hole process why that on of the product unit if defect for my section that mean it cant
select for particular order but it can be select for another type of order. Then in hole process defects
may be minimum ,but difficult to zero because environmental conditionals ex dust condition.
However I have done my project only for my section . So there is many defects .I tried to minimize
one defect per selected order because it may influence some improvement of the process on spec .
In this case I could analyze what are the reasons for product should be defect then I do some
suggestions to minimize defects and done some work study to reduce defects .the result of that I
could increase sigma value from previous level .